Bladed disk brush roller assembly for a vacuum cleaner

ABSTRACT

A brush roller assembly for a vacuum cleaner includes a rotatable spindle having a longitudinal axis, a first end, a second end and a central portion. A first airflow enhancing device (“AED”) is positioned, by being molded onto or operationally attached to, the first end of the rotatable spindle. The first AED includes a central portion, which is positioned substantially perpendicular to the longitudinal axis of the rotatable spindle when the first AED is positioned on the first end of the rotatable spindle. The first AED includes at least one fan blade projection outwardly extending from the periphery of the central portion of the first AED. The fan blade projection facilitates the movement of debris directly or indirectly from the first end of the rotatable spindle toward the central portion of the rotatable spindle. A second AED device may be positioned on the second end of the rotatable spindle, wherein the second AED has similar structure to and attaches in similar fashion as the first AED. In one embodiment, the housing has a hole in the bottom to enable air to enter the housing, travel down the longitudinal axis and towards the central portion of the rotatable spindle. In another embodiment, the housing may have openings in the sidewalls that promote airflow directly from the outside of the housing to the ends of the rotatable spindle. In yet another embodiment, a pressurized fan is attached to the housing or the rotatable spindle to increase forced airflow.

I. BACKGROUND OF THE INVENTION

A. Field of Invention

The present invention relates generally to new and novel improvements ina bladed disk brush roller assembly for a vacuum cleaner. Moreparticularly, the present invention relates to a bladed disk brushroller assembly for a vacuum cleaner which generates direct and/orindirect force that moves debris, such as dirt and dust, away from theends of the brush roller assembly including but not limited to thebearing assemblies toward the middle of the brush roller assembly whereit is removed from the brush roller assembly by the suction of thevacuum cleaner.

B. Description of Related Art

Brush roller assemblies for vacuum cleaners are well known and have beendescribed in numerous references, including a number of issued UnitedStates patents. A typical brush roller assembly includes a rotatablymounted and motor driven spindle having a brush on a cylindrical ornon-cylindrical outer surface thereof and a non-rotatable mountingstructure at each end to mount the brush roller assembly to a vacuumcleaner housing. While the mounting structure may vary considerably, onetype of known mounting structure includes end assemblies at each end ofthe spindle, the end assemblies including a rotatable stub shaft, abearing and an end cap member which is fixedly secured to the vacuumcleaner housing.

Certain problems are known to exist with known prior art of brush rollerassemblies for vacuum cleaners. In particular, debris, such as dirt anddust, tends to collect in such known prior art brush roller assemblies.This is thought to be due, at least in part, to the lack of movement ofair from the ends of the brush roller assembly to the central portion ofthe brush roller assembly where debris, such as dirt and dust, can beremoved from the brush roller assembly by the vacuum of the vacuumcleaner.

II. SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is the provision of anairflow enhancing device (“AED”), which includes, but is not limited to,bladed disks, fans, impellers, and other mechanical structures thatincrease air flow. The AED brush roller assembly for a vacuum cleaner,which facilitates the movement of debris from the ends of the brushroller assembly to the central portion of the brush roller assemblywhere it can be removed from the brush roller assembly by the vacuum ofthe vacuum cleaner assembly.

This and other objects of the present invention are attained by a brushroller assembly for a vacuum cleaner which includes a rotatable spindlehaving a longitudinal axis, a first end, a second end and a centralportion, a first AED positioned on the first end of the rotatablespindle, the first AED including a central portion which is positionedsubstantially perpendicular to the longitudinal axis of the rotatablespindle when the first AED is positioned on the first end of therotatable spindle and at least one fan blade (impeller or similarmechanical structure) projection outwardly extending from the peripheryof the central portion of the first AED, the one or more fan bladeprojections being oriented to facilitate the movement of debris from thefirst end of the rotatable spindle toward the central portion of therotatable spindle, a first end cap attached to the first end of therotatable spindle, a second AED (impeller or similar mechanicalstructure) positioned on the second end of the rotatable spindle, thesecond AED including a central portion which is positioned substantiallyperpendicular to the longitudinal axis of the rotatable spindle when thesecond AED is positioned on the second end of the rotatable spindle andat least one fan blade projection outwardly extending from the peripheryof the central portion of the second AED, the one or more fan bladeprojections being oriented to facilitate the movement of debris from thesecond end of the rotatable spindle toward the central portion of therotatable spindle and a second end cap attached to the second end of therotatable spindle.

Other advantages and novel features of the present invention will becomeapparent in the following detailed description of the invention whenconsidered in conjunction with the accompanying drawings.

III. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an AED brush roller assembly for avacuum cleaner in accordance with a preferred embodiment of the presentinvention.

FIG. 2 is a perspective view of an AED brush roller assembly for avacuum cleaner in accordance with another embodiment of the presentinvention.

FIG. 3 is a first exploded prospective view of the preferred embodimentof an AED brush roller assembly for a vacuum cleaner in accordance withthe present invention shown in FIG. 1.

FIG. 4 is a second exploded prospective view of the preferred embodimentof an AED brush roller assembly for a vacuum cleaner in accordance withthe present invention shown in FIG. 1.

FIG. 5 is a perspective view of the housing.

FIG. 6 is a perspective view of the housing showing the rotatablespindle.

FIG. 7 is a perspective view of the rotatable spindle.

FIG. 8 is an enlarged perspective view of the rotatable spindle shown inFIG. 1.

FIG. 9 is an enlarged perspective view of the rotatable spindle shown inFIG. 2.

FIG. 10 is a perspective view of the rotatable spindle showing thedirection of airflow.

FIG. 11 is another embodiment of the present invention showing openingsin the bottom of the housing.

FIG. 12 is yet another embodiment of the present invention showingcompletely open openings in the sidewalls of the housing, which may alsobe adjustable.

FIG. 13 is still another embodiment of the present invention showinganother embodiment of the airflow enhancement device in communicationwith the rotatable spindle to increase forced airflow through thehousing.

FIG. 14 is another embodiment of the present invention showingadjustable openings in the sidewalls of the housing.

FIG. 15 is a side view of FIG. 14 showing the adjustment mechanism inthe open position to enable airflow.

FIG. 16 is a side view of FIG. 14 showing the adjustment mechanism inthe closed position, which prevents airflow.

IV. DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following detailed description of a preferred embodiment of thepresent invention, reference is made to the accompanying drawings,which, in conjunction with this detailed description, illustrate anddescribe a preferred embodiment of an AED brush roller assembly for avacuum cleaner in accordance with the present invention. Referring toFIGS. 1-4, AED brush roller assembly 10 includes rotatable spindle 12having a generally cylindrical configuration and at least one brush 14,which is preferably positioned on the outer cylindrical surface ofrotatable spindle 12. The rotatable spindle 12 may have many differentgeometries, including an alternate embodiment shown in FIG. 2, which isrectangular. Rotatable spindle 12 includes two (2) end portions 16, ofwhich only one (1) is shown in FIGS. 3 and 4, and central portion 18.Rotatable spindle 12 also preferably includes recess 20 in each of endportions 16 and opening 22, which removably receives outwardly extendingpin 24. Rotatable spindle 12 is preferably fabricated from wood,although, if desired, a plastic material or some other material mayalternatively be used. Outwardly extending pin 24 is preferablyfabricated from steel, although, if desired, some other material may beused. AED brush roller assembly 10 also preferably includes two (2)bearings 26 positioned in central portion 30 of each AED 28 and overoutwardly extending pin 24 to facilitate the rotation of rotatablespindle 12.

AED brush roller assembly 10 also includes two (2) AEDs 28 positioned oneach end portion 16 of rotatable spindle 12. It should be noted that theAEDs 28 may be attached to any area along the rotatable spindle 12. AEDs28 include central portion 30 which is positioned substantiallyperpendicular to the longitudinal axis of rotatable spindle 12 when AEDs28 are placed on end portions 16 of rotatable spindle 12 and at leastone fan blade projection 32 outwardly extending from the periphery ofcentral portion 30 of AEDs 28. More specifically, the periphery is a lip31 extending from the central portion 30, wherein the lip has a firstside 31 a adjacently located to the central portion and a second side 31b, which is distally located from the first side 31 a. The one or morefan blade projections 32 of AEDs 28 are preferably oriented at an anglerelative to central portion 30 of AEDs 28 to facilitate the movement ofoutside air from end portions 16 of rotatable spindle 12 toward centralportion 18 of rotatable spindle 12 where outside air, as well as anydebris 70, such as dirt and dust, carried with the outside air, isremoved from AED brush roller assembly 10 by the air flow of the vacuumcleaner. Each blade projection 32 has a top 54 and a bottom 56. Furthereach blade 32 has a first face 58, which is flush with the second side32 b of the lip 31. Each blade 32 also has a second face 60, which mayextend approximately midway across the lip 31. The angle of one or morefan blade projections 32 of AEDs 28 relative to central portion 30 ofAEDs 28 is preferably in the range of zero (0) to ninety (90) degreesand is most preferably approximately twenty (20) degrees. Each bladeprojection 32 may have substantially the same cross sectional shape fromthe top 54 of the blade 32 to the bottom 56 of the blade 32. The angleof the top 54 and bottom 56 of the blade projections 32 relative to thecentral portion 30 may be equal. AEDs 28 are preferably fabricated froma plastic material, or alternatively, are fabricated as sheet metalstampings, although, if desired, other materials may be used.

As previously described, the airflow enhancing device (“AED”) may takethe form of a bladed disk. Alternatively, the AED may take the form ofany structural device that increases airflow, including, but not limitedto fans and impellers.

AED brush roller assembly 10 also includes two (2) end caps 34 attachedto bearings 26 in such a manner as to permit rotation of rotatablespindle 12 and AEDs 28. End caps 34 preferably include at least oneopening, and more preferably a plurality of openings 36 elongated in aradial direction positioned in a circular configuration approximatelycorresponding to the position of one or more fan blade projections 32 onAEDs 28, to facilitate the movement of outside air from end portions 16of rotatable spindle 12 toward central portion 18 of rotatable spindle12 where outside air, as well as any debris 70 (FIG. 6), such as dirtand dust, carried with the outside air, is removed from AED brush rollerassembly 10 by the airflow of the vacuum cleaner. End caps 34 preferablyinclude recess 38 and AEDs 28 are preferably positioned, at least inpart, in recess 38 of end caps 34. In addition, a portion of centralportion 30 of the AEDs 28 may be positioned in recess 20 in end portions16 of rotatable spindle 12. The AED 28 may be operationally connected ina variety of ways, including but not limited to, insertion in recess 20,screwed onto the brush roller assembly 10 and/or molded into the brushroller assembly 10. End caps 34 are preferably fabricated from a plasticmaterial, although, if desired, other materials may be used to fabricateend caps 34. In addition, if desired, rotatable spindle 12 and AEDs 28could be fabricated as an integral integrated assembly.

With reference to FIGS. 5-16, several alternative embodiments of thepresent invention will now be described. It should be understood thatthe end caps 34 previously described may be utilized in connection withthe embodiments described below if desired. The brush roller assembly 10is enclosed by a housing 40 having a top 42, a bottom 44 and sidewalls46. The housing 40 should have at least one opening 48 in sidewall 46 aand a second opening 50 in sidewall 46 b. The first end 16 a of therotatable spindle 12 is laterally spaced from the first opening 48, andthe second end 16 b of the rotatable spindle 12 is laterally spaced fromthe second opening 50. As such, air is adapted to enter the housingthrough the first and second openings 48, 50 and travel along thelongitudinal axis towards the central portion 18 of the rotatablespindle 12 so as to increase air flow and aid in the removal of debris70, which is best seen in FIG. 10. It should be noted that the airentering the first and second openings 48, 50 will generally be clean,meaning substantially uncontaminated by debris 70. Because of theairflow through the first and second openings 48, 50, debris to becollected near the side walls 46 is conveyed to the central portion 18,thus, enhancing edge cleaning.

With reference to FIGS. 10 and 11, another embodiment of the presentinvention is shown. In this embodiment, the bottom 44 of the housing 40has one or more openings or apertures 52 in addition to a primarycentral opening A. Although not required, it is preferred that theopenings 52 in the bottom 44 of the housing 40 be positioned in closeproximity to the sidewalls 46. With this configuration, air entersthrough the bottom apertures 52 outboard of end caps 34 and travelsalong the longitudinal axis rotatable spindle to the central portion 18.Air entering the housing 40 from the bottom aperture 52 will most likelybe contaminated with debris 70. In this embodiment, the sidewalls 46 a,46 b, may have the first and second openings 48, 50 to simultaneouslydraw in clean air 72 during operation. Further, this embodiment mayutilize the AED 28 as previously described or no AED. Edge cleaning isalso enhanced in this embodiment.

FIG. 12 shows yet another embodiment of the present invention. In thisembodiment the first and second openings 48, 50 are completely open,meaning there are no subdivisions as shown in FIGS. 1-3. Further, thereare no obstructions, such as a brush, between the sidewall openings 48,50 and the ends 16 of the rotatable spindle 12. Air entering the housingenters the openings 48, 50 and flows directly to an area in closeproximity to one of the corresponding end 16 a, 16 b, of the rotatablespindle 12 toward the central portion 18. In this configuration, airflowinput is greatly enhanced, as well as edge cleaning.

With reference to FIG. 13, another embodiment of the present inventionis illustrated. In this embodiment, an airflow adjustment mechanism 62takes the form of a pressurization mechanism, such as but not limited toa pressurized fan, is in airflow communication with one of the ends 16of the rotatable spindle 12. The airflow adjustment mechanism 62 may beattached to the housing or the rotatable spindle through any means knownin the art. The forced airflow may utilize the normal exhaust from themain vacuum in combination with appropriate ducting (not shown). As withthe other embodiments, this embodiment increase forced airflow fromoutside the housing, down the longitudinal axis of the rotatable spindle12 towards the central portion 18.

FIGS. 14-16 show yet another embodiment of the present invention. Inthis embodiment the first and second openings 48, 50 are adjustable. Anadjustment mechanism 100 is shown which varies the size of the openings48, 50. The adjustment mechanism 100 may be any device, but not limitedto a movable plate 102, as shown in FIG. 15. The movable plate 102 maybe rotated to vary the size of the openings 48, 50. When the adjustmentmechanism 100 is in a first position, as shown in FIG. 15, air enteringthe housing enters the openings 48, 50 and flows directly to an area inclose proximity to one of the corresponding end 16 a, 16 b, of therotatable spindle 12 toward the central portion 18. Whereas, when theadjust mechanism 100 is in a second position, as shown in FIG. 16, theopenings 48, 50 are closed an air cannot pass through. The adjustmentmechanism 100 may be moved to any position between completely open andcompletely closed in order vary and achieve the desired airflow.

Accordingly, although the present invention has been described above indetail, the same is by way of illustration and example only and is notto be taken as a limitation on the present invention. It is apparent tothose having a level of ordinary skill in the relevant art that othervariations and modifications in AED brush roller assembly for a vacuumcleaner in accordance with the present invention, as described and shownherein, could be readily made using the teachings of the presentinvention. Accordingly, the scope and content of the present inventionare to be defined only by the terms of the appended claims.

1. An apparatus, comprising: a housing having a first opening and asecond opening; a rotatable spindle positioned within the housing, therotatable spindle having a longitudinal axis, a first end, a second endand a central portion, the first end being laterally spaced from thefirst opening of the housing, the second end being laterally spaced fromthe second opening of the housing; an airflow enhancing means having acentral portion which is positioned substantially perpendicular to thelongitudinal axis of the rotatable spindle when the airflow enhancingmeans is placed on one of the ends of the rotatable spindle, whereindebris is mechanically acted on directly or indirectly and travels alongthe longitudinal axis towards the central portion of the rotatablespindle wherein said airflow enhancing means is driven by the rotatablespindle.
 2. The apparatus of claim 1, wherein the airflow enhancingmeans further comprises at least one blade extending radially therefrom,the blade having a base and top.
 3. The apparatus of claim 2, whereinthe airflow enhancing means is integrally molded into said rotatablespindle.
 4. The apparatus of claim 2, wherein the airflow enhancingmeans is physically attached to said rotatable spindle.
 5. The apparatusof claim 4, wherein the airflow enhancing means is attached to saidrotatable spindle by screws.
 6. The apparatus of claim 4, wherein theairflow enhancing means is attached to said rotatable spindle by beingpressed onto a stub shaft.
 7. The apparatus of claim 2, wherein theblade is angled relative to said central portion of the airflowenhancing means to facilitate the movement of outside air from saidfirst end of said rotatable spindle toward the central portion of saidrotatable spindle.
 8. The apparatus of claim 1, wherein the airflowenhancing means comprises at least one blade oriented at an anglebetween zero (0) degrees and ninety (90) degrees relative to the centralportion of the airflow enhancing means to facilitate the movement ofdebris toward the central portion of said rotatable spindle.
 9. Theapparatus of claim 1, further comprising a second airflow enhancingmeans having a central portion which is positioned substantiallyperpendicular to the longitudinal axis of the rotatable spindle when thesecond airflow enhancing means is placed on one of the ends of therotatable spindle, wherein debris is acted upon to travel along thelongitudinal axis towards the central portion of the rotatable spindle.10. A brush roller assembly for a vacuum cleaner, the brush rollerassembly comprising: a housing having a top, a bottom, and sidewalls,each of the sidewalls having at least one opening, the bottom having anaperture defined therein; a rotatable spindle positioned within thehousing, the rotatable spindle having a longitudinal axis, a first end,a second end and a central portion, the first end and second ends beinglaterally spaced from the opening of the sidewalls; an airflow enhancingmeans for increasing the flow of air toward said central portion of saidrotatable spindle, said airflow enhancing means having a central portionwhich is positioned substantially perpendicular to the longitudinal axisof the rotatable spindle when the airflow enhancing means is placed onone of the ends of the rotatable spindle, wherein air is adapted toenter the housing through the aperture defined in the bottom of thehousing and the openings in the sidewalls so as to travel along thelongitudinal axis towards the central portion of the rotatable spindleto increase air flow and wherein said airflow enhancing means is drivenby the rotatable spindle.
 11. The brush roller assembly of claim 10,wherein said airflow enhancing means is a bladed disk.
 12. The brushroller assembly of claim 11, wherein the disk further comprises at leastone blade extending radially therefrom, the blade having a base and atop.
 13. The brush roller assembly of claim 11, wherein the airflowenhancing means further comprises a plurality of blades extendingradially therefrom, each of the blades having a base and a top, whereintwo adjacent blades have a space defined between them to facilitate themovement of outside air and/or debris from the first end of saidrotatable spindle toward the central portion of said rotatable spindle.14. The brush roller assembly of claim 13, wherein the top and the baseof at least one blade of the airflow enhancing means is oriented at anangle between zero (0) degrees and ninety (90) degrees relative to thecentral portion of the airflow enhancing means to facilitate themovement of outside air and debris from the first end of said rotatablespindle toward the central portion of said rotatable spindle.
 15. Thebrush roller assembly of claim 11, further comprising a second airflowenhancing means, said second airflow enhancing means being a second diskhaving a central portion which is positioned substantially perpendicularto the longitudinal axis of the rotatable spindle when said secondairflow enhancing means is placed on one of the ends of the rotatablespindle, wherein air is adapted to enter the housing through the atleast one openings and travel along the longitudinal axis towards thecentral portion of the rotatable spindle so as to increase air flowtoward said central portion of said rotatable spindle.
 16. A brushroller assembly for a vacuum cleaner, said brush roller assemblycomprising: a housing having a top and first and second sidewalls; arotatable spindle positioned within the housing, the rotatable spindlehaving a longitudinal axis, a first end, a second end and a centralportion; an airflow enhancing means for increasing the flow of airtoward said central portion of said rotatable spindle, said airflowenhancing means having a central portion which is positionedsubstantially perpendicular to the longitudinal axis of the rotatablespindle when the airflow enhancing means is placed on one of the ends ofthe rotatable spindle, wherein the housing has at least one adjustableopening defined in the first sidewall of the housing to facilitate themovement of outside air through the opening and directly to one of theends of the rotatable spindle toward the central portion of therotatable spindle and wherein said airflow enhancing means is driven bythe rotatable spindle.